Permobil Koala User manual

SERVICE MANUAL
Koala
US

Produced and published by Permobil AB, Sweden
Edition no.5, 2006-01
Article no.: 201164-US-0
How to contact Permobil
Head Office of the Permobil group
Permobil Inc. USA
6961 Eastgate Blvd.
Lebanon, TN 37090
USA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Permobil AB
Box 120, 861 23 Timrå, Sweden
Tel: [phone]. Fax: [phone]
E-mail: [email protected]

Contents
4
Contents
Introduction.................................................................................................. 5
Technical support...................................................................................... 5
Spare parts ............................................................................................... 5
Warranties ................................................................................................ 5
Maintenance ............................................................................................. 5
Data Plates ................................................................................................... 6
Chassis..................................................................................................... 6
Pilot Motor Controller................................................................................ 6
Control panel ............................................................................................ 6
Operating the seat elevator manually ....................................................... 7
Covers........................................................................................................... 8
Batteries ....................................................................................................... 9
Drive wheels............................................................................................... 10
Brake release cables ................................................................................. 11
Brake release sensor................................................................................. 11
Magnetic brakes......................................................................................... 12
Drive motors............................................................................................... 13
Seat elevator .............................................................................................. 18
Actuators ................................................................................................. 18
Gas springs ........................................................................................... 19
Slide bearings ........................................................................................ 19
Pilot Motor Controller................................................................................ 20
SLS drive stage & seat function board ................................................... 21
Control panel.............................................................................................. 22
Seat control panel ..................................................................................... 22
Circuit breaker and fuses ......................................................................... 23
Circuit breaker ........................................................................................ 23
Charge fuse ............................................................................................ 24
Fuse for seat/lights ................................................................................. 24
Troubleshooting......................................................................................... 25
Distribution chart....................................................................................... 26

5
Introduction
Introduction
The Service Manual is intended for technical personnel who maintain and repair electric wheelchairs.
It is important that anyone who performs maintenance and repairs described in this manual reads and
understands the content of this manual so that the work is performed professionally. Always state the
chassis number when contacting Permobil to ensure that the correct information is provided.
Technical Support
In the event of technical problems, you should contact your dealer, or Permobil Inc. USA at 800-736-0925.
Spare parts
Spare parts must be ordered through your dealer.
Warranties
Contact your dealer or Permobil Inc. USA for information about the warranties for this chair.
Maintenance
See the information in the Owner’s Manual.

6
Data plates
Chassis
Rating plates
Control panel
Pilot Motor Controller
Fig. 1. Chassis identification number
Fig. 2. Pilot Motor Controller identification
number.
Fig. 3. Control panel identification number.

7
Operating the seat lift manually
Fig. 4. Connecting the cable for
emergency operation.
Operating the seat lift
manually
If you can not move the seat up in the normal way,
because the battery is flat or there is a fault (other
than in the lift mechanism), you can raise the seat
by using a cable, part number 308515-00-0.
1. Disconnect the connector in the lift mechanism
cable. You can get to it from underneath,
beside the rear fixing of the lift mechanism,
see fig. 4.
2. Connect the cable to the lift mechanism and a
battery or other voltage source, not exceeding
24 VDC. An ordinary 12V car battery is
sufficient to operate the seat lift on a
temporary basis.
If you do not have a cable for emergency
operation, or the lift mechanism is faulty, you can
raise the seat manually.
1. Remove the cushion from the seat.
2. Remove the seat plate, it is attached by three
bolts, see fig. 5.
3. Remove the front fixing from the lift
mechanism, see fig. 6.
4. Lift the seat manually to its highest position,
lock the seat in the upper position using the
safety stop. See fig. 7.
Fig. 5. The seat plate is attached by three bolts.
Fig. 6. Lift mechanism front fixing. Fig. 7. Seat lift safety stop.
The seat is heavy. Exercise caution when the
bolt is removed.

8
Covers
Covers
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Unscrew the two knobs that hold the front
edge of the battery cover, see fig. 8.
3. Lift the battery cover at the front edge and
move it backwards. Disconnect the connector
in the cable to the anti-trap mechanism before
you lift the cover off completely, see fig. 8.
4. Remove the chassis cover. It is held by two
screws at the front edge and two on either
side, see fig. 9-10.
Fitting
Fitting is the reverse procedure.
Fig. 8. The battery cover is attached by two knobs
at the front edge. Be careful with the anti-trap
mechanism cable.
Fig. 9. The chassis cover is attached by two
screws at the front edge.
Fig. 10. The chassis cover is attached by two
screws on either side. 9
Use caution when you remove the battery
cover. The anti-trap mechanism cable is
attached to the electronic unit.

9
Batteries
Batteries
Removal
1. Put the wheelchair on a level surface.
2. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
3. Switch off the main switch on the control panel.
4. Put the circuit breaker to the “OFF” position,
see fig. 11.
5. Remove the battery cover, see page 8.
6. Disconnect the battery leads, positive
terminals first, see fig. 12.
7. Remove the spacer plate at the front of the
battery compartment by pulling it straight
upwards, see fig. 13.
8. Lift out the batteries.
Fitting
Fitting is the reverse procedure.
On
Off
Fig. 11. Circuit breaker/Battery isolator.
Fig. 12. Battery connections.
Fig. 13. Remove the spacer plate from the battery
compartment by pulling it straight upwards.
Use caution when you remove the battery
cover. The anti-trap mechanism cable is
attached to the electronic unit.
Use protective goggles when working on
batteries.

10
Drive wheels
Fig. 14. Puller 304103-99-0.
Drive wheels
Removal
1. Switch off the main switch.
2. Lift up the chair and support it on blocks, so
that the wheels are off the ground.
3. Undo and remove the hubcap (6), bolt (3) and
the three washers (1 and 2), see fig. 15.
4. Pull the wheel off the shaft. Use puller
304103-99-0 if the wheel is tight, see fig. 14.
Fitting
1. Check the axle and rim for any damage. If
necessary, you should clean these parts of dirt
and rust. If any parts are damaged, they
should be replaced.
2. Check that the key fits solidly in the keyway of
the axle. If necessary, install the new key (4 or
5) and check for fit.
3. Lubricate the shaft with a thin layer of copper
paste (Würth 0893800x, Art. no.: 1820540).
Fig. 15. Wheel attachment.
Warning! Other types of bolts or washers are not
to be used..
Warning! Do not use any other type of thread lock.
Warning! Do not use any type of lubrication in the
threaded hole in the axle or on the bolt.
If necessary, you should clean these parts.
4. Fit the wheel onto the axle. The use of hand
force only is preferred, but, if need be,
carefully use a rubber mallet, whose head
diameter is no less than 1.5 inches (38 mm), to
ensure that the rim is fully seated upon the motor.
NB! Hitting too hard with a rubber mallet could
cause damage to the gear.
5. Mount the three washers (1) and (2) onto the
bolt (3) and secure the wheel. Use a torque
wrench to tighten the bolt to 24 ft-Ibs (33Nm).
Install the hub cap (6). See Fig. 14.
NB! The washer (1) should be placed with the
most flat side inwards.
NB! The bolt must be used once only. Removed
bolt is not allowed to be refitted.
1. Washer, 8 HB 305 Fe/Zn 5 C2 (TBRSB 8,4x26x5)
2. Shim washer DIN 988 8 A2 (DB 8x14x0.5 Rostfri)
3. Bolt, ISO 4762 M8x25 10.9 Fe/Zn 5 C2 /
Locking coat DIN 267-28
4. Key DIN 6885A 6x6x16
5. Key DIN 6885A 6x6x22
6. Hubcap
6
3
2
1
4
5
2

Brake release cables
11
Fig. 17. Brake release system.
12
Brake release cables
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Remove the battery cover and chassis cover,
see page 8.
3. Remove the brake release mechanism, it is
attached by two bolts, see fig. 16.
4. Slacken the locknut, see fig. 17:2.
5. Screw the adjusting screw fully in,
see fig. 17:1.
6. Detach the cable at the magnetic brake and
brake release mechanism.
Fitting
1. Attach the cable to the brake release
mechanism, then to the magnetic brake.
2. Adjust the length of the cable sleeve using the
adjusting screw (17:1), so that the cable is
tensioned but does not pull the release link.
3. Check the operation. Operate the brake
release mechanism to release the brake and
check that the wheel can turn.
4. Tighten the locknut (17:2).
5. Refit the brake release mechanism.
6. Refit the covers.
Brake release sensor
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Switch off the main switch on the control panel.
3. Put the circuit breaker to the “OFF” position,
see page 23, fig. 52.
4. Remove the battery cover and chassis cover,
see page 8.
5. Remove the brake release mechanism, it is
attached by two bolts, see fig. 16. It is easier to
remove the brake release sensor with the brake
release mechanism removed.
6. Remove the brake release sensor, it is
attached by two screws, see fig. 18.
7. Disconnect the connector in the brake release
sensor cable.
Fitting
Fitting is the reverse procedure.
Fig. 16. The brake release mechanism is
attached by two bolts.
Fig. 18. The brake release sensor is attached by
two screws.

12
Fig. 19. The magnetic brake and drive motor
electrical connectors.
Magnetic brake
Fig. 20. Remove the brake release cable.
Fig. 21. Drive motor fixing bolts.
Magnetic brakes
Removal
1. Put the wheelchair on a flat surface.
2. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
3. Switch off the main switch on the control panel.
4. Put the circuit breaker to the “OFF” position,
see page 23, fig. 52.
5. Remove the battery cover and chassis cover,
see page 8.
6. Disconnect the magnetic brake and drive motor
electrical connectors, see fig. 19.
7. Pull the cable sleeve forwards and take the
cable out through the slot in the cable
mounting, Unhook the brake release cable
from the magnetic brake, see fig. 20.
8. Raise the relevant side of the chair using the
Permojack or raise the chair on blocks.
9. Remove the drive wheel on the relevant side,
see page 10.
10. Remove the three bolts that hold the drive
motor, see fig. 21.

Magnetic brake
13
Fig. 22. Lifting up the rear end of the motor
makes the magnetic brake more accessible.
Fig. 23. Magnetic brake fixing bolts.
11. Lift up the rear end of the drive motor to make
it easier to remove the magnetic brake,
see fig. 22.
12. Remove the three bolts that hold the brake,
see fig. 23. Note the position of the brake
release arm and rubber seal for refitting.
Remove the brake, complete with the disc
and cover.

14
Magnetic brake
Fitting
1. Use the adjusting screws to adjust the
magnetic brake. Set both screws flush with
back surface of the brake, then turn the screws
downwards 1/8 turn, see fig. 24.
2. Fit the brake disc into the magnetic brake.
3. Fit the cover.
4. Insert a bolt (26:1) to align the parts.
Fig. 24. Use the two adjusting screws
to adjust the brake.
Fig. 25. Magnetic brake, brake disc, cover
and rubber seal removed.
Fig. 26. Use a bolt (1) to align the parts.
1
2

15
Magnetic brake
5. Fit the rubber seal, with the drainage hole at the
bottom. Note the position of the brake release
arm, fit the brake so that the brake release arm is
aligned with motor cable mounting. Secure the
magnetic brake using the three bolts.
6. Refit the drive motor, see fig. 21 on page 12.
7. Refit the drive wheel, see page 10.
8. Fit the brake release cable, see fig. 28.
9. Connect the magnetic brake and drive motor
electrical connectors, see fig. 29.
10. Fit the battery cover and chassis cover,
see page 8.
Fig. 28. Fit the brake release cable.
Fig. 27. Use one of the bolts to align the parts
with one another. Fit the rubber seal.
Fig. 29. Magnetic brake and drive motor
electrical connectors.

16
Drive motor
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Switch off the main switch on the control panel.
3. Put the circuit breaker to the “OFF” position,
see fig. 30.
4. Remove the battery cover and chassis cover,
see page 8.
5. Disconnect the drive motor and magnetic
brake electrical connectors, see fig. 31.
6. Pull the cable sleeve forwards and take the
cable out through the slot in the cable mounting.
Unhook the brake release cable from the
magnetic brake, see fig. 32.
Drive motor
Fig. 31. Disconnect the electrical connectors.
Fig. 32. Disconnect the brake release cable.
Fig. 30. Circuit breaker, 63A (Off-On).
On
Off

17
7. Remove the front battery, see page 9.
8. Raise the relevant side of the chair using the
Permojack or raise the chair on blocks.
9. Remove the drive wheel on the relevant side
the wheelchair, see page 10.
10. Remove the three bolts holding the motor.
Fitting
Fitting is the reverse procedure. When fitting a
new motor, use the cable mounting from the old
motor.
Drive motor
Fig. 33. Drive motor fixing bolts.
Fig. 34. Removing the drive motor.

18
Seat lift
Seat lift
Actuators
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Switch off the main switch on the control panel.
3. Put the circuit breaker to the “OFF” position,
see page 23, fig. 52.
4. Remove the battery cover and chassis cover,
see page 8.
5. Remove the seat cushion and seat plate,
see fig. 35.
6. Remove the seat lift actuators front fixing bolt,
see fig. 36.
7. Lift the seat manually to its highest position.
Ensure that the safety stop is in place, see fig. 37.
8. Disconnect the connector in the seat lift
actuator cable.
9. Remove the seat lift actuator rear fixing
bolt, see fig. 38.
Fitting
Fitting is the reverse procedure.
Fig. 35. The seat plate is attached by three bolts.
Fig. 36. Seat lift mechanism front fixing.
Fig. 37. Seat lift safety stop. Fig. 38. Seat lift actuators rear fixing.
The seat is heavy. Exercise caution when the
bolt is removed.

19
Gas springs
There are gas springs built into the parallel tubes
at the sides of the seat lift. These gas springs are
part of the tilt mechanism.
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Remove the battery cover and chassis cover,
see page 8.
3. Switch off the main switch on the control panel.
4. Put the circuit breaker to the “OFF” position,
see page 23, fig. 52.
5. Remove the bolt to detach the rear end of the
spring, see fig. 39:2 and 40:8. Lock the pivot
arm (40:2) by inserting a drift from underneath,
through the hole in the end of the parallel tube.
6. Remove the circlip from the front attachment
point, see fig. 39:1 and 40:3.
7. Remove the parallel tube complete with the
gas spring.
8. Remove the socket head cap screw that locks
the adjuster (40:1) and remove the tube.
9. Drive out the spring tension pin (40:5) and
remove the gas spring attachment (40:4).
10. Drive out the spring tension pin (40:7) and
remove the tube.
Fitting
Fitting is the reverse procedure
Slide bearings
Changing a bearing
The basic procedure for changing a bearing is the
same for all bearings
1. Remove the part where the bearing is to be
changed.
2. Deform the bearing by driving a drift through
the hole in the bearing seat, see fig. 41. Pull
out the deformed bearing using pliers.
3. Clean the bearing seat and press, or carefully
drive, in the new bearing. Turn the bearing so
that the slot is aligned with the hole used when
deforming the bearing, in order to make the
next bearing change easier.
4. Refit the part with the new bearing.
Seat lift
1
2
Do not drill into the tube or gas spring, and do
not expose them to heat, as this could cause an
explosion.
1
4
6
5
8
3
7
2
1. Bolt, MC6S
2. Pivot arm
3. Circlip, SgA 16
4. Gas spring attachment
5. Spring tension pin, 8 x 18
6. Gas spring
7. Spring tension pin, 8 x 20
8. Bolt, 8 x 16
Fig. 41. Hole for deforming the bearing.
Fig. 39. Parallel tube with gas spring.
Fig. 40. Parallel tube with gas spring.

20
Pilot Motor Controller
Removal
1. Raise the seat to its highest position. To
operate the seat lift manually, see page 7.
2. Switch off the main switch on the control panel.
3. Put the circuit breaker to the “OFF” position,
see page 23, fig. 52.
4. Remove the seat lift cover and chassis cover,
see page 8.
5. Lift the Pilot Motor Controller out of its holder,
see fig. 42-43.
6. Disconnect the electrical connectors from the
output stage; note their locations for refitting,
see fig. 44.
Fitting
Fitting is the reverse procedure.
Pilot Motor Controller
Fig. 42. The Pilot Motor Controller sits in
its holder without any fixings.
Fig. 43. Lift up the Pilot Motor Controller.
Fig. 44. Electrical connectors for the
Pilot Motor Controller.